Power or line switches for controls



Jan. 21, 1958 W. K. NEWMAN ETAL POWER OR LINE SWITCHES FOR CONTROLS Filed July 5, 1955 Hill!!! In ATTORNEY 2,820,864 Patented Jan. 21, 1958 ice POWER on LINE SWITCHES FOR coNrnoLs William K. Newman and George 0. Puerner, Indianapoiis,

Ind, assignors to l. R. Mallory & Co., Inc, Indianapolis, 11111., a corporation of Delaware Application July 5, 1955, Serial No. 519,824

10 Claims. (Cl. 200-67) This invention relates to electric switches and refers more particularly to snap switches including those of the type mounted on the back of volume controls and which are designed to switch fairly heavy currents used in radio and television circuits and sets.

By the very nature of their use, the size of these switches is important since relatively small dimensions are characteristic of the specifications and dimensions set forth in these circuits. They are thus generally housed in casings of small diameter and shallow depth wherein the requisite spring action or movement range becomes exceedingly diflicult to obtain. This is the more so when it is understood that for efiicient operation of the switch it is desirable that efiicient contact make-and-break be afforded. Moreover, at the same time it is desirable to achieve desirable contact mating action between the 0 contacts and, in substance, obtain prolonged life therebetween as a result of the efficient, self-cleaning and nonarcing characteristics built into the switch. These features are the desiderata of such switches and determine the efficiency, stability, durability and economy of the switch. Heretofore, these characteristics were difficult to attain and required complex and multiple components for the switches, which added to the cost of fabrication thereof.

The present invention now provides a simple, economical and efficient snap switch wherein all the above desired features are obtained at a minimum of cost as to labor and material, and wherein a small, compact, highly efficient structure is obtained having optimum calibration and alignment characteristics.

it is therefore an object of the present invention to provide an improved snap switch for operating under heavy current conditions, said switch being exceedingly simple in construction and efiicient in resultant operation.

It is another object of the present invention to provide a power or line switch for volume controls wherein said switch is constructed with floating contacts held in a loose fashion on a rotor of insulating material so that a desirable self-aligning feature is accomplished in the operation of the switch, resulting in long life and optimum current carrying conditions therein as a result of the non-arcing and positive contact make-and-break characteristics thereof.

Still another object of the present invention is to provide a new and novel snap switch having free moving contacts centered on elongated moulded bosses and which are adapted upon rotation of the cooperating moulded rotor to make contact with stationary termini in a manner such that said contacts are adapted to rotate about said bosses to achieve a self-aligning characteristic and thus make for a more efficient contact engagement with the terminals of said switch.

Another object of the present invention is to provide a small, heavy current type of snap action switch utilizing a spring for motivating a rotor moulded of insulator material having extruded bosses upon which are mounted free moving contact rings adapted to cooperate with stationary termini in a manner such that said switch has improved characteristics of make-and-break between the contacts and the termini and a longer life, inasmuch as said contacts are adapted to give a self-aligning effect in the make-and-break operations of the switch.

An added object of the present invention is to provide a switch construction wherein substantially no current is allowed to pass through a spring which would cause high temperatures to be generated and cause annealing and consequent loss of contact pressures.

It is another object of the present invention to provide a simple, economical and efficient snap action switch having desired characteristics of quick make-and-break, long life and positive mating atcion and wherein its ring type contacts are such as to make for a more efficient transmittal of current between the same and its associated termini of the switch.

Still another object of the present invention is to provide a new type of switch whose contacts on the snap action of the rotor are rotatable about moulded bosses integrally formed on said rotor and wherein said contacts are rings adapted to move about a dimension of the bosses on said rotor so as to obtain new contact make-and-break with the termini upon repeated utilization of the switch so as to prolong the life thereof and to give better operating characteristics thereto.

Another object of the present invention is to provide a new and improved snap action switch having novel contact element-s consisting of rings mounted on extruded bosses of a moulded rotor which is adapted to be motivated by a compression spring element so as to move said elements in and out of engagement with fixed termini in a positive manner and to give more etiicient operation and durablity thereto.

With the above and other objects in view, which will appear as the description proceeds, this invention resides in a novel construction combination and arrangement of parts substantially as hereinafter described and more particularly defined by the appended claims, it being understood that such changes in the precise embodiment of the invention here disclosed may be made as come within the scope of the claims.

The invention in another of its aspects relates to the novel features of the instrumentalities described herein for teaching the principal objects of the invention and to the principles embodied in these in-strumentalities, whether or not these features and principles may be used in the said objects and/ or in similar fields.

The accompanying figures of the drawing illustrate both a double pole version and a single pole version of the new and novel ring contact snap action switch, as illustrated by the physical embodiment of the invention constructed in accordance with the best mode so far devised for the practical application of the principles thereof and in which:

Fig. 1 is a longitudinal sectional view showing a double pole embodiment of the switch as illustrating the present invention and as adapted to be mounted on the back of a volume control, said switch being in the closed position;

Fig. 2 is a cross sectional view taken through Fig. 1 on the plane of the line 22 and looking into the switch; and

Fig. 3 is a top view of an embodiment of the switch as adapted to illustrate the open position of the ring contact elements loosely held on the bosses of the moulded rotor of a double pole switch.

Generally speaking the switch is basically in its single pole embodiment, a contact ring carried and driven by an elongated boss on a rotor of insulating material into contact or bridging position between two terminals. The elongated boss has its longest center-line coincident.

or very nearly so, with the line of force into the contacts. This boss shape gives very little play in the driving direction and at the same time provides a great deal of t tu s ee erin ee nin t de ees h line f f e Pavin fo e i i te t e re ra n t i e ti n de ired by-th -eve en e act o of a toggle spring, ,andmotion of the rotor is limited by the cup in the off position and by the contacts in the on position. v

The double pole version of the switch is smiliar to the above construction with, however, several other structures incorporated therein. As stated, in the single pole version one pair of contacts limit the motion .of the rotor in the on position. Therefore, it will be readily e n t at an addit na pel req ires a on c v n compliance in order to mechanically seat two contact ri a tea .PQ E IS- Th b id n ng and t e erm na us fo se s-m sale a pa t dent cal t th s used in the single pole with the terminals ,;set at uptimum angles for good, reliable contact. e pr ss sp in is use t d e he s cond rin i o t c en agementb tantial y round os o th rotor, which isapproximately centered in the ring when contact is made, is the means for driving the second ring o th o f Position. I

It has been found during tests conducted on the contacts that in both cases the ring turns and presents new contact surfaces to the stationary terminals. The ring driven by the elongated boss is adapted to vibrate around the boss while the switch is in the off position .or during the snap on or snap off operation. In the second case of the spring loaded ring the rotation thereof comes from the operation of approaching one terminal a split second earlier and rolling on the pressure spring until contact is made with the other terminal.

Referring now particularly to the accompanying drawing, in which like numerals indicate similar parts, Fig. 1 is a plan view of the switch as illustrating a double pole, single throw, A. C.-D. C., heavy current switch.

Reference numeral 11 designates the base of the switch which consists of a circular disc of suitable insulating material and serves to close one end of a cylindrical metal cup or shell 1;. The shell and cup thus constitute a substantielly u -sh ed sw tch h usin 3 As has been stated, the switch is adapted to be mounted n h ba k f device tl ol m contro s or the like a d ac di gl the s ch i so ne tively e gaged .L l af to be a ate cnthe rot nthereo by mean 9t e coupl r or can. .wh...l s apted. t m e e aets ter 4 9f the sw 1 na mu h as hi invention is more directly concerned with the swit h, Per t is i i iez t to P i ou hat. the ca d p to swing between defined limits as determined by a crescent shaped, cut-out portion formed the bottom side of the switch casing.

Actuator 14 comprises a unitarily formed metal struct a n a Pi Q P 2 f rme on n i e ther of and an arc-like platform ,on the other side thereof, said platform having two vertical dependencies extending down therefrom for cooperating with the driver coupler of the volume control portion of the assembly for turnn he t leto t AFIOSS f om the i o pos 24 h c a an een e ted to th s de t ereo a lateral extension having an aperture cut therethrough which is adapted to accept one end of a toggle spring as herein: after described.

in this fashion, actuator 14 will be adapted to move a rotor base 17 which supports free moving contact rings 15 and 19 thereupon as seated on bosses 30 and 31 in tegrally formed and connected to one side of the rotor. Rotor 11 is of a thin, cross-sectional, moulded construction having upper and lower surfaces 21 and 22 defining a predetermined configuration. As seen from the drawings, the rotor is of substantially thin cross-section having a hollow bore orcollar 23 adapted to accept and conln ad ition,

fine pivot post 24 of the actuator 14. From the apex formed by collar 23, two sides 25 and 26 of the rotor extend'angularly to meet .with sides 27 and 28 placed substantially at right angles thereto. These latter sides are joined with an end wall 29, to give the entire rotor a tapered head construction, with the mid-portion thereof having a somewhat rectangular construction wi-ththree sides thereof being somewhat bowed.

On surface 2l there is formed integrally joined bosses 3% and 31. Bosses '30 and 3 1 are moulded-to surface 21, with boss 3% being moulded as'a rectangular support of narrow cross-section about which contact ring'19 is adapted to fit and is loosely hcldthereon. Boss 31 is formed as a round post extending from surface 21.

in the modification exemplified for the double pole, single throw switch shown in Figs. 1-3 a pressure spring post 33 is also formed and moulded to the surface 21.

ends thereof retained thereby .to form solder lugs.

h s po n n unct i h s ller. 12 is, adap t ontain pres ur sp ng, so that c nt c s is motivated thereby on its boss 31 under pressure ofp Por n o the sp ing- Spring .37 is .a-th leaf sprin having and portions '40 and 41 interconnected to a mid-portion 42. Portions At) and 41 extend out from the mid-portion 42 so that each lies ,fiat, 'first, against contact ring 15 on post 31 to restrain .it thereon, and, next, on collar 23. The mid-portion of the spring is placed about post 33 in a manner suchthat the entire spring takes on a sinuated form with thenccessary .constraint being applied against boss 31 and collar 23. The other contact ring-19 is loosely mounted onboss 30, which is rectangular in configuration and is maintained thereby on the rotor.

In the assembly of the switch, each of the contact rings, loosely held or free floating in construction, is adapted to mate with sets of terminals, i. e., either and 51 or 52 and 53. These terminals are adapted to penetrate a terminal base .11 to be staked therein with the Terminals 50 and 51 are directed toward each other at angles adapted to form a V, while the other set of terminals 52 and 53 are placed in the base in a manner such as to contain the contact ring situated on the round boss. These latter terminals, in conjunction with the pressure spring, are adapted to loosely hold the said ring on its cooperating boss.

In order to move the contact rings in and out of contact with their cooperating terminals, a toggle spring is adapted to be connected to therotor to move the same upon movement ,of actuator 14. This is accomplished by connecting spring 60 to the actuator by means of'an end 61 of the spring fitting within aperture 62 of the actuator. correspondingly, an end 63 of the spring is adapted 'to fit within a slot 64 formed in a U-shaped'retainer 65 moulded to the underside of the rotor. Thus, by movement of the actuator 14 rotor 17 is adapted to move the contacts in and out of engagement with their corresponding terminals.

In the single pole version of the switch embodying the principle of the free floating contact ring, it is necessary to have only two terminals 50 and 51 and one circular contact ring 19 held on a rectangular boss 30. In this construction there is no pressure spring and the free floating ring contact moves in and out of engagement with its terminals by movement of the actuator which has a' toggle spring interconnecting it and the rotor via moulded retainer '65 in a manner substantially as described above. It is noted, therefore, that all parts for single pole switches are identical to double pole parts except that terminal plate 11 has two holes eliminate from it and several parts are omitted. e

The free floating characteristics of the contact rings loosely held on their bosses achieve greater contactetiiciency, inasmuch as by their movements about their bosses more chance of contact making new surfaces are offered between the rings and their terminals, thus making for. an efiicient, self-aligning type of contact engagemm; The switch action is thus more positive in nature and provides self-aligning characteristics. The life of the switch is greatly prolonged and a much more efiicient switch is provided. This switch, constructed according to the specifications herein described, has thus provided a great advance in the art.

From the foregoing description, taken in connection with the accompanying figures of the drawing, it will be readily apparent to those skilled in the art that this invention provides a new and improved switch, the features of which may be applied to other arts and devices. Accordingly, it is contemplated that the scope of the invention is to be determined from the claims herein.

We claim:

1. An electric switch comprising a metal casing having an open end, a flat base of insulating material placed in said open end to close the same, unitarily constructed electric terminals having soldering lugs attached thereto inserted in said base, said terminals being predeterminedly angularly disposed therein, an actuator for said switch, said actuator including a pivot post, means in said casing for limiting the movement of said actuator, a rotor connected to said actuator to be moved thereby, said rotor including a hollow bore fittable over said pivot post of said actuator to move thereabout and to position said rotor in said casing, a pair of sides of said rotor extending at an angle from said bore to form a tapered area thereby, another portion of said rotor joined to said tapered area to complete the extent of the rotor, said latter area being somewhat rectangular in shape, said rotor further having a plurality of bosses formed on a surface thereof, and individual ring contact means adapted to fit over individual bosses of said rotor, means bearing against said bore, a contact ring, and a boss thereof with said ring contact means being free moving about said boss on said rotor to cooperate with said predetermined spaced terminals to afiord positive contact action and improved current transfer characteristics for the said switch.

2. An electric comprising a metal casing having an open end, a flat base of insulating material placed in said open end to close the same, unitarily constructed electric terminals having soldering lugs attached thereto inserted in said base, said terminals being predeterminedly angularly disposed therein, an actuator for said switch, said actuator including a pivot post, means in said casing for limiting the movement of said actuator, a toggle spring, a rotor connected to said actuator by said toggle spring to be moved thereby, said rotor being of thin cross-section between its upper and lower surfaces, including a hollow bore fitta'ble over said pivot post of said actuator to move thereabout and to position said rotor in said casing, a pair of sides of said rotor extending at an angle from said bore to form a tapered area thereby, another portion of said rotor joined to said tapered area to complete the extent of the rotor, said latter area being somewhat rectangular in shape, said rotor further having a plurality of dissimilarly shaped bosses formed on its upper surface, individual annular contact means adapted to fit over individual bosses of said rotor, and pressure means bearing against said base, said annular contact means and boss with said annular contact means being free moving about the boss on said rotor to cooperate with said predetermined spaced terminals to afford positive contact action and improved current transfer characteristics for the said switch.

3. An electric switch comprising a metal casing having an open end, a flat base of insulating material placed in said open end to close e same, unitarily constructed electric terminals having soldering lugs attached thereto inserted in said base, said terminals being predeterminedly angularly disposed therein, an actuator for said switch, said actuator including a pivot post and an aperture 6 formed therethrough at a point opposite said post, means in said casing forlimiting the movement of said actuator, a rotor of thin cross-section between its upper and lower surfaces, said lower surface having a moulded slot, an over center toggle spring connected to said aperture of said actuator and said slot of said rotor, said rotor thus being moved by said actuator and spring, said rotor further including a hollow bore fittable over said pivot post of said actuator to move thereabout and to position said rotor in said casing, a pair of sides of said rotor extending at an angle from said bore to form a tapered area thereby, another portion of said rotor joined to said tapered area to complete the extent of the rotor, said latter area being somewhat rectangular in shape, said rotor further having a plurality of differently dimensioned bosses formed on its upper surface thereof, ring contact means adapted to fit over the individual bosses of said rotor, and resilient bearing means placed against said ring contact means, said ring contact means being free moving about each boss on said rotor to cooperate with said predetermined spaced terminals to afford positive contact action and improved current transfer characteristics for the said switch.

4. An electric switch comprising a metal cup having an open end, a flat base of insulating material placed in said open end to close the same, unitarily constructed electric terminals having soldering lugs attached thereto inserted in said base, said terminals being predeterminedly angularly disposed therein, a metal actuator for said switch, said actuator including a pivot post and an aperture formed therethrough at a point opposite said post, means on said actuator and in said casing for limiting the movement of said actuator, a moulded rotor connected to said actuator by a loaded toggle spring to be moved thereby, said rotor including a moulded collar fittable over said pivot post of said actuator to move thereabout and to position said rotor in said cup, a pair of sides of said rotor extending at an angle from said bore to form a tapered area thereby, another portion of said rotor joined to said tapered area to complete the extent of the rotor, said latter area being somewhat rectangular in shape, said rotor further having a plurality of bosses formed on a surface thereof, individual ring contact means adapted to fit over some of said bosses of said rotor, said ring contact means being free moving about the bosses on said rotor to cooperate with said predetermined spaced terminals, and a pressure spring bearing against a contact ring on one boss, said spring also bearing against another moulded boss and said collar on said rotor to aid in the positioning of said latter contact ring with respect to its terminals and whereby positive contact action and improved current transfer characteristics are obtained for said switch.

5. An electric switch comprising a metal casing of cup-like configuration having an open end, a thin, flat base of insulating material placed in said open end to close the same, unitarily constructed electric terminals having integrally formed soldering lugs attached thereto inserted in said base, said terminals being predeterminedly angularly disposed therein, a metal actuator for said switch, said actuator including a pivot post and an aperture formed therethrough at a point opposite said post, dependent means on said actuator and means in said casing for limiting the movement of said actuator, a moulded rotor having a slot connected to said actuator by a loaded toggle spring connected to said aperture of said actuator and said slot of said rotor to be moved thereby, said rotor also including a hollow bore fittable over said pivot post of said actuator to move thereabout and to position said rotor in said casing, a pair of sides of said rotor extending at an angle from said bore to form a tapered area thereby, another portion of said rotor joined to said tapered area to complete the extent of the rotor, said latter area being somewhat rectangular in shape, said rotor further having a plurality of bosses 6. electric switch comprising a metal casiuglhaw casing, fixed electrical terminal means for said switch carried on said base, an 'actuator'ltayihg a PiVQt'POSt for ing a'c'up configuration, =a flat insulating Ease closin said saidswitch, andrga moulded rotor adapted t'o lie moved by said actuator, said rote: having a colrar fittin ever said piyo't post "and having a plurality of integrally formed bosses of differing diziinefri configuration placed,

thereon adapted for carrying lo'os'efring contacts i and out of engagement with said terminals 'so as to allow urrent to ass thereby, said ring contact having resilient bearing'r'nerins Jplace'd thcre'ag'ain'stto allow for fp'bsitivc Contact action and optimum transfereharaeteristtcs.

7. An electric'switch enmpri'sing'ametal casing, 21 flat base of insulating material closing said casing, electrical terminal means for said switch mounted on said base, an actuator for said switch, a rotor adapted to be moved by a toggle spring connected to said actuator said rotor having a plurality of moulded bosses-formed thereon, a pair of said bosses adapted for carrying free moving contacts, and a pressure Spring placed against another of said bosses on said rotor, said spring adapted 'to aid inlmaintainin'g one of said 'freemoving contacts on it's bosses so that proper engagement is had therebetween and the terminals of said switch.

8. An electric switchcompr'ising 'a casing, electrical terminal means on a fiat insulating base for closing said aaaaaa;

easing as an 'switch an actuator fie; when 563 a rotorh'aviifrg difieifently configured b sses theiebii adapted to -be moved by said actuato'gone, "of bosses having bearing means applied tlier'eag nst for carrying 'a loose ing contact in and "out of n gmnt with said terminals *so' a's'to allow current "to p'a 9. An electric switch comprising'a rn'etalfcas'm fix'ed electrical terminal means mounted ona flat base for said switch, said base closing saicLc-asir'ig'v o n switcman actuator for said switch, and a'rotor; adapted to be moved in a plane parallel'to said metal casin'g by a togglespring connected to said actuator, saidfrotor having dissimilar "shaped bosses and spring meansJcQ- operating therewith for resurainedly carrying loosening contacts in and out of engagement with said terminals so as to allow current to pass thereby.

terminal means for said switch, "an "ac tuator forfsaid switch, and a rotor having ai'plural'ity ofbos'ses adapted Y to'be moved by said 'aetuatoriin a plane parallel said casing,w said rotor having spring means toraidiii'g' in carrying loose ringco'ntacts placed around said bosses in and out of engagemcntwith said terminal's soas'to allow current to passtlie'reby.

References Citedm the fileof this patent UNITED STATES PATENTS 2,131,590 Hathorn Sept. 2 8, 1938 2,303,516 Von 'Mehren .Dec. '1, 1942 2,524,784 Franks Ct 211. "Oct. 10,1950 261K714. D'rcssel Nov. '18, 19 52 2, 3 ,951 Fahringer Apr. 28, 1953 7 2,636,952 Fah'ring'er Apr. '28, 1953 2,660,633 Vaksv'ik a Nov. 24, 1953 

